Downhole setting tool

ABSTRACT

A downhole setting tool includes an upper cylinder, and a piston positioned in the upper cylinder. A charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder. The tool also includes a mandrel coupled to the upper cylinder. A flow port is defined in the mandrel, the flow port being in fluid communication with the first hydraulic chamber. The tool further includes a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, and the flow port being in fluid communication with the second hydraulic chamber. The lower cylinder is configured to move with respect to the mandrel when the setting tool is actuated.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Applicationhaving Ser. No. 62/960,323, which was filed on Jan. 13, 2020 and isincorporated herein by reference in its entirety.

BACKGROUND

In the oil and gas field, a variety of downhole tools may be employed toperform various functions in the well. For example, a packer may bedeployed into the well and set therein to isolate one section fromanother. A setting tool is typically employed to set the packer. Thesetting tool may include a central mandrel that pulls up on acorresponding mandrel of the packer (or other type of tool such as aplug), and a setting sleeve that pushes down on a collar or anothermember of a setting assembly of the packer. The setting tool isactuated, e.g., by detonating a charge therein, to push downward on thesleeve holding the mandrel stationary. This results in the settingassembly being axially compressed and radially expanded, and therebysetting into the wellbore.

However, the setting tools are prone to failure, as they typically relyon several relatively movable pistons, rods, sleeves, etc. for movementof the setting sleeve and/or mandrel.

SUMMARY

Embodiments of the disclosure may provide a downhole setting tool. Thetool includes an upper cylinder, and a piston positioned in the uppercylinder. A charge chamber is defined on one side of the piston withinthe upper cylinder, and a first hydraulic chamber is defined on anopposite side of the piston and within the upper cylinder. The tool alsoincludes a mandrel coupled to the upper cylinder. A flow port is definedin the mandrel, the flow port being in fluid communication with thefirst hydraulic chamber. The tool further includes a lower cylindercoupled to the head of the mandrel, the mandrel and the lower cylinderdefining a second hydraulic chamber within the lower cylinder, and theflow port being in fluid communication with the second hydraulicchamber. The lower cylinder is configured to move with respect to themandrel when the setting tool is actuated.

Embodiments of the disclosure may also provide a method for setting adownhole tool. The method includes coupling a mandrel of the downholetool to a setting tool. The setting tool includes an upper cylinder, anda piston positioned in the upper cylinder. A charge chamber is definedon one side of the piston within the upper cylinder, and a firsthydraulic chamber is defined on an opposite side of the piston andwithin the upper cylinder, the first hydraulic chamber having hydraulicfluid therein. The setting tool also includes a mandrel attached to theupper cylinder. The mandrel of the setting tool is coupled the mandrelof the downhole tool. The setting tool further includes a lower cylindercoupled to the mandrel, the mandrel and the lower cylinder defining asecond hydraulic chamber within the lower cylinder, the second hydraulicchamber being in fluid communication with the first hydraulic chamber.The method further includes deploying the tool and the setting tool intoa wellbore, and detonating a charge in the charge chamber of the settingtool. Detonating the charge causes a force to be applied to the piston.Applying the force to the piston causes the piston to force at leastsome of the hydraulic fluid to flow from the first hydraulic chamber tothe second hydraulic chamber. Causing at least some of the hydraulicfluid to flow from the first hydraulic chamber to the second hydraulicchamber causes the lower cylinder to move with respect to the mandreland to apply a setting force to the downhole tool.

Embodiments of the disclosure also provide a downhole setting toolincluding an upper cylinder comprising a sub configured to contain acharge, the upper cylinder at least partially defining a first hydraulicchamber therein, a piston positioned in the first chamber and movablewith respect to the upper cylinder in response to detonating the charge,and a mandrel including a head coupled to the upper cylinder anddefining a flow port therein. The piston moving in response to thecharge detonating is configured to cause hydraulic fluid to flow fromthe first hydraulic chamber and through the flow port. The mandrel alsoincludes an extension extending from the head and configured to coupleto a subjacent tool so as to apply an axially-directed force thereto.The setting tool also includes a lower cylinder received at leastpartially around the mandrel and comprising a shoulder that is sealedwith the extension of the mandrel. The shoulder and the head of themandrel define a second hydraulic chamber axially therebetween, thefirst and second hydraulic chambers being in fluid communication withone another via the flow port. The setting tool further includes one ormore retaining members connecting the lower cylinder to the head of themandrel. The one or more retaining members are configured to release andallow the lower cylinder to move relative to the mandrel and relative tothe upper cylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may best be understood by referring to thefollowing description and accompanying drawings that are used toillustrate some embodiments. In the drawings:

FIG. 1 illustrates a side, cross-sectional view of a downhole settingtool in a run-in configuration, according to an embodiment.

FIG. 2 illustrates a side, cross-sectional view of the downhole tool inan actuated configuration, according to an embodiment.

FIG. 3 illustrates a flowchart of a method for setting a downhole tool(e.g., a packer, plug, etc.) in a wellbore, according to an embodiment.

DETAILED DESCRIPTION

The following disclosure describes several embodiments for implementingdifferent features, structures, or functions of the invention.Embodiments of components, arrangements, and configurations aredescribed below to simplify the present disclosure; however, theseembodiments are provided merely as examples and are not intended tolimit the scope of the invention. Additionally, the present disclosuremay repeat reference characters (e.g., numerals) and/or letters in thevarious embodiments and across the Figures provided herein. Thisrepetition is for the purpose of simplicity and clarity and does not initself dictate a relationship between the various embodiments and/orconfigurations discussed in the Figures. Moreover, the formation of afirst feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed interposing the first and secondfeatures, such that the first and second features may not be in directcontact. Finally, the embodiments presented below may be combined in anycombination of ways, e.g., any element from one exemplary embodiment maybe used in any other exemplary embodiment, without departing from thescope of the disclosure.

Additionally, certain terms are used throughout the followingdescription and claims to refer to particular components. As one skilledin the art will appreciate, various entities may refer to the samecomponent by different names, and as such, the naming convention for theelements described herein is not intended to limit the scope of theinvention, unless otherwise specifically defined herein. Further, thenaming convention used herein is not intended to distinguish betweencomponents that differ in name but not function. Additionally, in thefollowing discussion and in the claims, the terms “including” and“comprising” are used in an open-ended fashion, and thus should beinterpreted to mean “including, but not limited to.” All numericalvalues in this disclosure may be exact or approximate values unlessotherwise specifically stated. Accordingly, various embodiments of thedisclosure may deviate from the numbers, values, and ranges disclosedherein without departing from the intended scope. In addition, unlessotherwise provided herein, “or” statements are intended to benon-exclusive; for example, the statement “A or B” should be consideredto mean “A, B, or both A and B.”

FIG. 1 illustrates a side, cross-sectional view of a downhole settingtool 100, according to an embodiment. The tool 100 may be configured toconnect to a subjacent tool, such as a packer, plug, etc., that is to beset into a wellbore. In one specific embodiment, the downhole settingtool 100 may be configured to push downward on an upper cone of adownhole tool, while pulling upward on a lower cone of the downholetool. In such an embodiment, the downhole tool may be provided as any ofthe downhole tools discussed in U.S. Pat. No. 10,408,012, which isincorporated herein by reference in its entirety, to the extent notinconsistent with the present disclosure. In other embodiments, thedownhole setting tool 100 may be configured to pull upward on a mandreland press downward on a setting assembly (e.g., slips, seals, cones,etc.) that is slidably positioned around the mandrel, as commonlyemployed in packers, plugs, etc.

In an embodiment, the tool 100 may include an upper cylinder 102 and alower cylinder 104. Although referred to as “cylinders,” it will beappreciated that this term, as used herein, includes geometries for thecylinders 102, 104 that may not be precisely cylindrical. For example,the cylinders 102, 104 may include shoulders, varying diameters, orother features as described herein or otherwise called for to supportthe functionality of the tool 100, while still being referred to as“cylinders”.

In at least one embodiment, the upper cylinder 102 may be formed from aplurality of members, e.g., a sleeve 106 and a sub 108 that arethreaded, fastened, or otherwise connected together, end-to-end. Thesleeve 106 may be generally hollow, and may at least partially define afirst hydraulic chamber 110 therein. The first hydraulic chamber 110 maycontain a generally incompressible hydraulic fluid, e.g., oil, therein.

The sub 108 may provide an upper connection 109 for the tool 100 toconnect to a tool string (e.g., wireline, slickline, coiled tubing,etc.), and a bore therethrough, which may define a charge chamber 112.The charge chamber 112 may be configured to contain a powder charge, orany other type of explosive power source. In some embodiments, the sub108 may also include a disc bleeder valve 116, which may be configuredto vent gas in the charge chamber 112, e.g., to avoid damage to the tool100 upon detonation of the powder charge.

The charge chamber 112 and the first hydraulic chamber 110 may beprevented from fluid communication therebetween by a piston 114. Thepiston 114 may be received within the upper cylinder 102, specificallywithin the sleeve 106, and may be sealed therewith. In the run-inconfiguration, as shown in FIG. 1, the piston 114 may also abut an endof the sub 108, and may be held in place by the hydraulic fluid fillingthe first hydraulic chamber 110, and/or may be pinned or otherwisetemporarily restrained in position. The piston 114 may be configured toslide within the sleeve 106, e.g., in response to detonation of thepowder charge in the charge chamber 112.

A mandrel 120 may be received through the lower cylinder 104 and intothe upper cylinder 102. For example, the mandrel 120 may be threadedinto or otherwise fastened to the upper cylinder 102, such that themandrel 120 may generally not move with respect thereto duringactuation. One or more restraining members 121 may be coupled to thelower cylindrical member 104 and to either or both of the upper cylinder102 or (as shown) the mandrel 120. The restraining members 121 maytemporarily fasten the lower cylinder 104 to the mandrel 120.Accordingly, the lower cylinder 104 may be configured to slide withrespect to the mandrel 120 during actuation, but may be prevented fromdoing so prior to actuation by the restraining members 121. The one ormore restraining members 121 may be shear pins, shear screws, clips,detents, or any other member configured to release upon exertion of apredetermined amount of force.

In an embodiment, the mandrel 120 may include a head 122 and anextension 124, with the head 122 defining a larger diameter than theextension 124, as shown. The head 122 and the extension 124 may beintegrally-formed or may be formed from two separate pieces that areconnected together. Further, the head 122 may be sealed with the lowercylinder 104 by one or more seals 123 so as to prevent fluid fromcommunicating from the first hydraulic chamber 110 around mandrel 120.The extension 124 may extend through a shoulder 126 formed in the lowercylinder 104, and may seal therewith. Moreover, the shoulder 126 may beconfigured to slide along the extension 124.

Further, the head 122 may define an end face 128, which may beaxially-oriented, where the extension 124 meets the head 122. A secondhydraulic chamber 130 may be defined axially between the shoulder 126and the end face 128. The head 122 may include a flow port 132 therein,which may communicate between the first and second hydraulic chambers110, 130. For example, as shown, the flow port 132 may include an axialbore 134 in the head 122 extending from the first hydraulic chamber 110,but not entirely through the head 122. The flow port 132 may alsoinclude one or more radial openings 136, which extend at least partiallyradially from the axial bore 134 and to an outer diameter of the head122, e.g., between the head 122 and the inner diameter of the lowercylinder 104, below (to the right of, as illustrated) the seals 123, andthus may fluidly communicate with the second hydraulic chamber 130 viathe unsealed interface between the head 122 and the lower cylinder 104.

In some embodiments, the tool 100 may include a mandrel adapter 140. Themandrel adapter 140 may be configured to engage the mandrel of thesubjacent tool and, upon actuation of the setting tool 100, to pullupward on the mandrel of the subjacent tool, as discussed above.Further, a lower end 142 of the lower cylinder 104 may be configured,upon actuation of the tool 100, to slide over and past the mandreladapter 140 and into engagement with the setting assembly of thesubjacent tool, so as to push downwardly thereon, as discussed above.The mandrel adapter 140 may also provide a lower stop for the movementof the lower cylinder 104, as will be described in greater detail below,thereby preventing the lower cylinder 104 from sliding away from thearound the mandrel 120.

FIG. 2 illustrates a side, cross-sectional view of the tool 100 in anactuated position, that is, after actuation of the tool 100, accordingto an embodiment. Actuation of the tool 100 may generally occur bydetonating the powder charge contained in the charge chamber 112.Detonation may expand the gas in the charge chamber 112 or otherwiseapply a force on the piston 114 directed in a downhole direction (to theright in FIG. 2). This force causes the piston 114 to move from theposition shown in FIG. 1 to that shown in FIG. 2.

The piston 114 moving causes the hydraulic fluid in the first hydraulicchamber 110 to flow through the flow port 132 and (e.g., directly) intothe second hydraulic chamber 130. However, the flow port 132, e.g., theradial openings 136, may be relatively small in cross-section, as shown,and the hydraulic fluid may be viscous. Accordingly, the flow port 132may serve to slow the movement of the piston 114, acting as a dashpot tolimit shock loading of the subjacent tool.

As the fluid is forced from the first hydraulic chamber 110 into thesecond hydraulic chamber 130, the restraining members 121 holding thelower cylinder 104 in place release (e.g., yield), allowing the lowercylinder 104 to slide relative to the mandrel 120. This allows thevolume of the second hydraulic chamber 130 to increase, as the pressureof the hydraulic fluid filling the second chamber 130 under forceapplied by the piston 114, drives the lower cylinder 104 away from theupper cylinder 102.

As the lower cylinder 104 is driven downhole, the mandrel 120 isprevented from moving with respect to the upper cylinder 102 and thusthe tool string via the connection with the upper cylinder 102. As notedabove, the mandrel 120 is connected to a subjacent mandrel, e.g., viathe mandrel adapter 140. The subjacent mandrel may thus likewise beprevented from movement with respect to the upper cylinder 102.

The lower cylinder 104, however, is driven downhole, extending the lowerend 142 thereof past the mandrel adapter 140, e.g., into engagement withthe subjacent tool (or any other structure employed to set the subjacenttool), and applying a downhole-directed force thereto. In someembodiments, the shoulder 126 may engage the adapter 140 at a bottom ofa downstroke of the lower cylinder 104, such that the adapter 140prevents the lower cylinder 104 from sliding off of the mandrel 120. Thecombination of the pushing and pulling may cause the subjacent tool toradially expand, and thereby set into position, e.g., sealing with asurrounding tubular (e.g., casing, liner, wellbore wall, etc.).

FIG. 3 illustrates a flowchart of a method 300 for setting a downholetool (e.g., packer, plug, etc.), according to an embodiment. For thesake of convenience, the downhole tool will be described as a packer,but it will be appreciated that this is merely an example. The method300 may proceed by operation of the downhole setting tool 100 discussedabove, and thus is described herein with reference thereto. However, itwill be appreciated that other embodiments may employ other structures.Further, although one illustrated sequence of steps is described belowfor the method 300, it will be appreciated that the order may bechanged, or the steps may be combined or separated into two or moresteps, without departing from the scope of the present disclosure.

The method 300 may begin by connecting a mandrel 120 of the downholesetting tool 100 to a packer, as at 302. In some embodiments, themandrel 120 may be connected to a mandrel of the packer, but in otherembodiments, the mandrel 120 may be connected to a cone or anothersetting tool. The method 300 may also include connecting an uppercylinder 102 of the downhole setting tool 100 to a tool string, as at304. The method 300 may then include running the tool string, includingthe setting tool 100 and the packer, into a wellbore, as at 306.

When the packer arrives at a desired position, the downhole setting tool100 may be actuated, as at 308. Actuating the downhole setting tool 100may be achieved by detonating a powder charge contained in a chargechamber 112 of the downhole setting tool 100. Further, detonating thepowder charge may drive a piston 114 in the upper cylinder 102 in adownhole direction. Driving the piston 114 in the downhole direction mayforce a hydraulic fluid contained in a first hydraulic chamber 110through a flow port 132 defined in the mandrel 120 and into a secondhydraulic chamber 130. The second hydraulic chamber 130 is definedbetween the mandrel 120 and a lower cylinder 104. Forcing fluid into thesecond hydraulic chamber 130 may cause one or more restraining members121 holding the lower cylinder 104 in place relative to the uppercylinder 102 to release, and may then cause the lower cylinder 104 tomove downward with respect to the mandrel 120.

The lower cylinder 104 may move downward into engagement with the packeror another setting tool, so as to set the packer. The mandrel 120 may beprevented from moving with respect to the tool string via connection tothe upper cylinder 102. Thus, the downward movement of lower cylinder104 may push downward on the packer, while the mandrel 120 pulls upwardon the mandrel or cone of the packer. As a result, a setting force(e.g., a downward force, an upward force, or a combination thereof) isapplied by the setting tool 100 onto the packer, thereby radiallyexpanding the packer, so as to set the packer in the wellbore.

The foregoing has outlined features of several embodiments so that thoseskilled in the art may better understand the present disclosure. Thoseskilled in the art should appreciate that they may readily use thepresent disclosure as a basis for designing or modifying other processesand structures for carrying out the same purposes and/or achieving thesame advantages of the embodiments introduced herein. Those skilled inthe art should also realize that such equivalent constructions do notdepart from the spirit and scope of the present disclosure, and thatthey may make various changes, substitutions, and alterations hereinwithout departing from the spirit and scope of the present disclosure.

What is claimed is:
 1. A downhole setting tool, comprising: an uppercylinder; a piston positioned in the upper cylinder, wherein a chargechamber is defined on one side of the piston within the upper cylinder,and a first hydraulic chamber is defined on an opposite side of thepiston and within the upper cylinder; a mandrel coupled to the uppercylinder, wherein a flow port is defined in the mandrel, the flow portbeing in fluid communication with the first hydraulic chamber; and alower cylinder coupled to the mandrel, the mandrel and the lowercylinder defining a second hydraulic chamber within the lower cylinder,and the flow port being in fluid communication with the second hydraulicchamber, wherein the lower cylinder is configured to move with respectto the mandrel when the downhole setting tool is actuated.
 2. Thedownhole setting tool of claim 1, wherein the charge chamber isconfigured to contain an explosive charge, wherein, detonating theexplosive charge forces the piston toward mandrel so as to move thelower cylinder.
 3. The downhole setting tool of claim 2, wherein thefirst and second hydraulic chambers are configured to contain ahydraulic fluid therein, such that, when the piston is forced toward themandrel, at least some of the hydraulic fluid is forced from the firsthydraulic chamber to the second hydraulic chamber.
 4. The downholesetting tool of claim 3, wherein the lower cylinder is configured toslide with respect to the mandrel, such that forcing the hydraulic fluidfrom the first hydraulic chamber to the second hydraulic chamber causesthe lower cylinder to slide so as to increase a volume of the secondhydraulic chamber.
 5. The downhole setting tool of claim 1, wherein thelower cylinder comprises a shoulder, and wherein the mandrel extendsthrough and seals with the shoulder.
 6. The downhole setting tool ofclaim 5, wherein the second hydraulic chamber is at least partiallydefined between an end face of a head of the mandrel and the shoulder.7. The downhole setting tool of claim 5, further comprising a mandreladapter that is connected to the mandrel, wherein the mandrel adapter isconfigured to engage the shoulder of the lower cylinder at a bottom of astroke of the lower cylinder.
 8. The downhole setting tool of claim 1,wherein the mandrel comprises a head that is connected to the uppercylinder, and an extension that extends from the head and through atleast a portion of the lower cylinder, and wherein the flow port extendsaxially into but not through the mandrel, and extends at least partiallyradially outward in the head into fluid communication with the secondhydraulic chamber.
 9. The downhole setting tool of claim 1, wherein themandrel is configured to apply an uphole-directed force on a mandrel ofa subjacent tool, and wherein the lower cylinder is configured to applya downhole-directed force on a setting assembly of the subjacent tool.10. The downhole setting tool of claim 1, further comprising one or moreshear members connecting the lower cylinder to the mandrel, wherein theone or more shear members are configured to shear to allow the lowercylinder to slide relative to the mandrel upon actuation.
 11. Thedownhole setting tool of claim 1, wherein the upper cylinder comprises:a sub in which the charge chamber is defined, the sub defining an upperconnection for the tool that is configured to be connected to a toolstring; and a sleeve in which the first hydraulic chamber is defined,the sleeve being connected to the mandrel, such that the mandrel isconfigured not to move with respect to the sleeve during actuation ofthe tool.
 12. The downhole setting tool of claim 11, wherein the mandrelcomprises: a head connected to the sleeve, wherein the lower cylinder isreceived around and sealed with the head, wherein the second hydraulicchamber is at least partially defined between an end face of the headand a shoulder of the lower cylinder; and an extension extending fromthe head and through the shoulder, the extension being sealed with theshoulder of the lower cylinder and configured to couple to a mandrel ofa subjacent tool.
 13. A method for setting a downhole tool, comprising:coupling a mandrel of the downhole tool to a setting tool, wherein thesetting tool comprises: an upper cylinder; a piston positioned in theupper cylinder, wherein a charge chamber is defined on one side of thepiston within the upper cylinder, and a first hydraulic chamber definedon an opposite side of the piston and within the upper cylinder, thefirst hydraulic chamber having hydraulic fluid therein; a mandrelattached to the upper cylinder, wherein the mandrel of the setting toolis coupled the mandrel of the downhole tool, and wherein the mandrel andis in fluid communication with the first hydraulic chamber; a lowercylinder coupled to the mandrel, the mandrel and the lower cylinderdefining a second hydraulic chamber within the lower cylinder that is influid communication with the first hydraulic chamber; deploying the tooland the setting tool into a wellbore; and detonating a charge in thecharge chamber of the setting tool, wherein detonating the charge causesa force to be applied to the piston, wherein applying the force to thepiston causes the piston to force at least some of the hydraulic fluidto flow from the first hydraulic chamber to the second hydraulicchamber, and wherein causing at least some of the hydraulic fluid toflow from the first hydraulic chamber to the second hydraulic chambercauses the lower cylinder to move with respect to the mandrel and toapply a setting force to the downhole tool.
 14. The method of claim 13,wherein the setting tool further comprises a flow port extending atleast partially through the mandrel and between the first and secondhydraulic chambers, and wherein detonating the charge presses the atleast some of the hydraulic fluid from the first hydraulic chamber,through the flow port, and into the second hydraulic chamber, expandingthe second hydraulic chamber.
 15. The method of claim 14, wherein theflow port comprises at least one radial opening communicating with thesecond hydraulic chamber, and wherein detonating the charge causes theat least some of the hydraulic fluid to flow through the at least oneradial opening, and from the at least one radial opening into the secondhydraulic chamber.
 16. The method of claim 13, wherein detonating causesthe lower cylinder to move axially past a lower end of the mandrel so asto press downwards on the downhole tool while the mandrel pulls upwardson the downhole tool.
 17. The method of claim 13, wherein the lowercylinder is positioned at least partially around the mandrel, andwherein detonating the charge causes the lower cylinder to slide alongan outer diameter surface of the mandrel.
 18. The method of claim 17,wherein the mandrel is coupled to and connects together the uppercylinder and the lower cylinder.
 19. The method of claim 18, wherein themandrel is connected to the lower cylinder via one or more restrainingmembers, and wherein detonating the charge causes the one or morerestraining members to yield, thereby permitting the lower cylinder toslide relative to the mandrel.
 20. A downhole setting tool, comprising:an upper cylinder comprising a sub configured to contain an explosivecharge, the upper cylinder at least partially defining a first hydraulicchamber therein; a piston positioned in the first hydraulic chamber andmovable with respect to the upper cylinder in response to detonating thecharge; a mandrel comprising: a head coupled to the upper cylinder anddefining a flow port therein, wherein the piston moving in response tothe charge detonating is configured to cause hydraulic fluid to flowfrom the first hydraulic chamber and through the flow port; and anextension extending from the head and configured to couple to asubjacent tool so as to apply an axially-directed force thereto; a lowercylinder received at least partially around the mandrel and comprising ashoulder that is sealed with the extension of the mandrel, wherein theshoulder and the head of the mandrel define a second hydraulic chamberaxially therebetween, the first and second hydraulic chambers being influid communication with one another via the flow port; and one or moreretaining members connecting the lower cylinder to the head of themandrel, wherein the one or more retaining members are configured torelease and allow the lower cylinder to move relative to the mandrel andrelative to the upper cylinder.